BODY COLLISION REPAIR

• HEADINGS
  • 00 - Technical data
    • Vehicle identification data
      • Type plate and vehicle identification number
      • Vehicle data sticker
    • Aluminum panels
      • Sill reinforcement
    • Foam-filled cavities
      • A-pillar
      • Front longitudinal member
      • C-pillar
    • Body panel gaps/shut lines
      • Body, front
      • Body, center
      • Body, rear
    • Laser welding
      • Laser welding
      • Laser welding (Sedan)
    • Bonded joints
      • Bonded joints
      • Spot-welded bonded joints
      • Bonded joints, inspecting and repairing
      • Repair methods for replacing body parts
      • Repair methods for bonded joints
        • Body, front
        • Body, center
        • Body, rear
    • Straightening jig
      • Straightening jig
      • Supplement for quattro versions
      • Portal gauge
    • Body dimensions
      • Floor group, front
      • Floor group, center
      • Floor group, rear
      • Body, front
      • Body, center
        • Front door opening
      • Body, center (Avant models - interior)
        • Rear door opening
        • Rear door opening (Avant)
      • Body, rear
      • Body, rear (Avant)
  • 50 - Body, Front
    • Intermediate piece, partial replacement
      • Procedure
        • Cutting locations
        • Replacement parts
        • Welding in
    • Upper wheel housing longitudinal member, replacement
      • Procedure
        • Cutting locations
        • Replacement part
        • Welding in
    • Front longitudinal member, partial replacement
      • Procedure
        • Cutting locations
        • Replacement part
        • Welding in
    • Front longitudinal member, replacement
      • Procedure
        • Cutting locations
        • Replacement parts
        • Welding in
  • 51 - Body, center
    • Roof, replacing
      • Procedure
        • Cutting locations
        • Replacement parts
        • Welding in
    • Roof, replacement (Avant)
      • Procedure
        • Cutting locations
        • Replacement parts
        • Welding in
    • Front roof cross member, replacement
      • Procedure
        • Cutting locations
        • Replacement part
        • Welding in
    • Rear roof frame, replacement
      • Procedure
        • Cutting locations
        • Replacement part
        • Welding in
    • Rear roof frame, replacement (Avant)
      • Procedure
        • Cutting locations
        • Replacement parts
        • Welding in
    • A-pillar, replacement
      • Procedure
        • Cutting locations
        • Replacement parts
        • Welding in
    • Inner A-pillar, replacement
      • Procedure
        • Cutting locations
        • Replacement part
        • Welding in
    • B-pillar, replacement
      • Procedure
        • Cutting locations
        • Replacement part
        • Welding in
    • Inner B-pillar, replacement
      • Procedure
        • Cutting locations
        • Replacement parts
        • Welding in
    • Inner side member, replacement
      • Procedure
        • Cutting locations
        • Replacement part
        • Welding in
    • Floor panel, partial replacement
      • Procedure
        • Cutting locations
        • Replacement part
        • Welding in
  • 53 - Body, rear
    • Rear cross panel (upper section), replacement
      • Procedure
        • Cutting locations
        • Replacement part
        • Welding in
    • Rear cross panel (upper section), replacement (Avant)
      • Procedure
        • Cutting locations
        • Replacement part
        • Welding in
    • Rear cross panel (upper section), replacement
      • Procedure
        • Cutting locations
        • Replacement part
        • Welding in
    • Rear cross panel (inner section), replacement
      • Procedure
        • Cutting locations
        • Replacement part
        • Welding in
    • Rear cross panel (inner section), replacement (Avant)
      • Procedure
        • Cutting locations
        • Replacement part
        • Welding in
    • Tail light mounting, replacement
      • Procedure
        • Cutting locations
        • Replacement part
        • Welding in
    • Rear mounting panel, partial replacement (Avant)
      • Procedure
        • Cutting locations
        • Replacement parts
        • Welding in
    • Rear lock carrier, replacement
      • Procedure
        • Cutting locations
        • Replacement parts
        • Welding in
    • Side panel, replacement
      • Procedure
        • Cutting locations
        • Replacement parts
        • Welding in
    • Side panel, replacement (Avant)
      • Procedure
        • Cutting locations
        • Replacement parts
        • Welding in
• FIGURES
  • Fig. 1: Locating Type Plate And Vehicle Identification Number
  • Fig. 2: Identifying Vehicle Data Sticker
  • Fig. 3: Sill Reinforcement
  • Fig. 4: Foam-Filled Cavities - A-Pillar
  • Fig. 5: Identifying Foam Insert & Expanded Foam Insert
  • Fig. 6: Identifying Foam-Filling Hole, Expanded Foam Inserts & Dampening Foam
  • Fig. 7: Identifying Body Panel Gaps/Shut Lines (Body, Front)
  • Fig. 8: Identifying Body Panel Gaps/Shut Lines (Body, Center)
  • Fig. 9: Identifying Body Panel Gaps/Shut Lines (Body, Rear)
  • Fig. 10: Identifying C-Pillar Laser-Welded To Inner Side Panel & Roof Laser-Welded To Outer Roof Frame
  • Fig. 11: Identifying Inner A-Pillar To Inner Side Panel, Inner B-Pillar To Inner Sill & Lock Reinforcement To Inner Side Panel
  • Fig. 12: Bonded Joints
  • Fig. 13: Spot-Welded Bonded Joints
  • Fig. 14: Identifying Repair Methods For Bonded Joints (Body, Front - A, B ,C, D, E, F, X)
  • Fig. 15: Identifying Repair Methods For Bonded Joints (Body, Front - G, H)
  • Fig. 16: Identifying Repair Methods For Bonded Joints (Body, Front - J, K, M)
  • Fig. 17: Identifying Repair Methods For Bonded Joints (Body, Center - A, B)
  • Fig. 18: Identifying Repair Methods For Bonded Joints (Body, Center - C)
  • Fig. 19: Identifying Repair Methods For Bonded Joints (Body, Center -D)
  • Fig. 20: Identifying Repair Methods For Bonded Joints (Body, Rear - A)
  • Fig. 21: Straightening Jig (1 Of 10)
  • Fig. 22: Straightening Jig (2 Of 10)
  • Fig. 23: Straightening Jig (3 Of 10)
  • Fig. 24: Straightening Jig (4 Of 10)
  • Fig. 25: Straightening Jig (5 Of 10)
  • Fig. 26: Straightening Jig (6 Of 10)
  • Fig. 27: Straightening Jig (7 Of 10)
  • Fig. 28: Straightening Jig (8 Of 10)
  • Fig. 29: Straightening Jig (9 Of 10)
  • Fig. 30: Straightening Jig (10 Of 10)
  • Fig. 31: Supplement For Quattro Versions (1 Of 3)
  • Fig. 32: Supplement For Quattro Versions (2 Of 3)
  • Fig. 33: Supplement For Quattro Versions (3 Of 3)
  • Fig. 34: Portal Gauge (1 Of 4)
  • Fig. 35: Portal Gauge (2 Of 4)
  • Fig. 36: Portal Gauge (3 Of 4)
  • Fig. 37: Portal Gauge (4 Of 4)
  • Fig. 38: Body dimensions - Floor Group, Front
  • Fig. 39: Body Dimensions - Floor Group, Center
  • Fig. 40: Body Dimensions - Floor Group, Rear
  • Fig. 41: Body Dimensions - Body, Front (1 Of 2)
  • Fig. 42: Body Dimensions - Body, Front (2 Of 2)
  • Fig. 43: Body Dimensions - Body, Center (Front Door Opening)
  • Fig. 44: Body Dimensions - Body, Center (Avant Models - Interior)
  • Fig. 45: Body Dimensions - Body, Center (Rear door opening)
  • Fig. 46: Body Dimensions - Body, Center (Rear Door Opening (Avant))
  • Fig. 47: Body Dimensions - Body, Rear
  • Fig. 48: Body Dimensions - Body, Rear (Avant)
  • Fig. 49: Intermediate Piece, Partial Replacement - Cutting Locations
  • Fig. 50: Intermediate Piece, Partial Replacement - Replacement Parts
  • Fig. 51: Intermediate Piece, Partial Replacement - Welding In (1 Of 2)
  • Fig. 52: Intermediate Piece, Partial Replacement - Welding In (2 Of 2)
  • Fig. 53: Upper Wheel Housing Longitudinal Member, Replacement - Cutting Locations
  • Fig. 54: Upper Wheel Housing Longitudinal Member, Replacement - Replacement Part
  • Fig. 55: Upper Wheel Housing Longitudinal Member, Replacement - Welding In
  • Fig. 56: Front Longitudinal Member, Partial Replacement - Cutting Locations
  • Fig. 57: Front Longitudinal Member, Partial Replacement - Replacement Part
  • Fig. 58: Front Longitudinal Member, Partial Replacement - Welding In
  • Fig. 59: Front Longitudinal Member, Replacement - Cutting Locations (1 Of 2)
  • Fig. 60: Front Longitudinal Member, Replacement - Cutting Locations (2 Of 2)
  • Fig. 61: Front Longitudinal Member, Replacement - Replacement Parts (1 Of 2)
  • Fig. 62: Front Longitudinal Member, Replacement - Replacement Parts (2 Of 2)
  • Fig. 63: Front Longitudinal Member, Replacement - Welding In (1 Of 4)
  • Fig. 64: Front Longitudinal Member, Replacement - Welding In (2 Of 4)
  • Fig. 65: Front Longitudinal Member, Replacement - Welding In (3 Of 4)
  • Fig. 66: Front Longitudinal Member, Replacement - Welding In (4 Of 4)
  • Fig. 67: Roof, Replacing - Cutting Locations (1 Of 3)
  • Fig. 68: Roof, Replacing - Cutting Locations (2 Of 3)
  • Fig. 69: Roof, Replacing - Cutting Locations (3 Of 3)
  • Fig. 70: Roof, Replacing - Replacement Parts
  • Fig. 71: Roof, Replacing - Welding In (1 Of 3)
  • Fig. 72: Roof, Replacing - Welding In (2 Of 3)
  • Fig. 73: Roof, Replacing - Welding In (3 Of 3)
  • Fig. 74: Roof, Replacement (Avant) - Cutting Locations (1 Of 3)
  • Fig. 75: Roof, Replacement (Avant) - Cutting Locations (2 Of 3)
  • Fig. 76: Roof, Replacement (Avant) - Cutting Locations (3 Of 3)
  • Fig. 77: Roof, Replacement (Avant) - Replacement Parts
  • Fig. 78: Roof, Replacement (Avant) - Welding In (1 Of 4)
  • Fig. 79: Roof, Replacement (Avant) - Welding In (2 Of 4)
  • Fig. 80: Roof, Replacement (Avant) - Welding In (3 Of 4)
  • Fig. 81: Roof, Replacement (Avant) - Welding In (4 Of 4)
  • Fig. 82: Front Roof Cross Member, Replacement - Cutting Locations
  • Fig. 83: Front Roof Cross Member, Replacement - Welding In
  • Fig. 84: Rear Roof Frame, Replacement - Cutting Locations
  • Fig. 85: Rear Roof Frame, Replacement - Welding In
  • Fig. 86: Rear Roof Frame, Replacement (Avant) - Cutting Locations
  • Fig. 87: Rear Roof Frame, Replacement (Avant) - Welding In (1 Of 2)
  • Fig. 88: Rear Roof Frame, Replacement (Avant) - Welding In (2 Of 2)
  • Fig. 89: A-Pillar, Replacement - Cutting Locations
  • Fig. 90: A-Pillar, Replacement - Cutting Locations
  • Fig. 91: A-Pillar, Replacement - Welding In
  • Fig. 92: Inner A-Pillar, Replacement - Cutting Locations
  • Fig. 93: Inner A-Pillar, Replacement - Replacement Part
  • Fig. 94: Inner A-Pillar, Replacement - Welding In
  • Fig. 95: B-Pillar, Replacement - Cutting Locations
  • Fig. 96: B-Pillar, Replacement - Replacement Part
  • Fig. 97: B-Pillar, Replacement - Welding In
  • Fig. 98: Inner B-Pillar, Replacement - Cutting Locations
  • Fig. 99: Inner B-Pillar, Replacement - Replacement Parts
  • Fig. 100: Inner B-Pillar, Replacement - Welding In
  • Fig. 101: Inner Side Member, Replacement - Cutting Locations
  • Fig. 102: Inner Side Member, Replacement - Replacement Part
  • Fig. 103: Inner Side Member, Replacement - Welding In
  • Fig. 104: Floor Panel, Partial Replacement - Cutting Locations
  • Fig. 105: Floor Panel, Partial Replacement - Replacement Part
  • Fig. 106: Floor Panel, Partial Replacement - Welding In
  • Fig. 107: Rear Cross Panel (Upper Section), Replacement - Cutting Locations
  • Fig. 108: Rear Cross Panel (Upper Section), Replacement - Replacement Part
  • Fig. 109: Rear Cross Panel (Upper Section), Replacement - Welding In
  • Fig. 110: Rear Cross Panel (Upper Section), Replacement (Avant) - Cutting Locations
  • Fig. 111: Rear Cross Panel (Upper Section), Replacement (Avant) - Replacement Part
  • Fig. 112: Rear Cross Panel (Upper Section), Replacement (Avant) - Welding In
  • Fig. 113: Rear Cross Panel (Upper Section), Replacement - Cutting Locations
  • Fig. 114: Rear Cross Panel (Upper Section), Replacement - Welding In
  • Fig. 115: Rear Cross Panel (Inner Section), Replacement - Cutting Locations
  • Fig. 116: Rear Cross Panel (Inner Section), Replacement - Replacement part
  • Fig. 117: Rear Cross Panel (Inner Section), Replacement - Welding In
  • Fig. 118: Rear Cross Panel (Inner Section), Replacement (Avant) - Cutting Locations
  • Fig. 119: Rear Cross Panel (Inner Section), Replacement (Avant) - Welding In
  • Fig. 120: Tail Light Mounting, Replacement - Cutting Locations
  • Fig. 121: Tail Light Mounting, Replacement - Replacement Part
  • Fig. 122: Tail Light Mounting, Replacement - Welding In
  • Fig. 123: Rear Mounting Panel, Partial Replacement (Avant) - Cutting Locations
  • Fig. 124: Rear Mounting Panel, Partial Replacement (Avant) - Replacement Parts
  • Fig. 125: Rear Mounting Panel, Partial Replacement (Avant) - Welding In (1 Of 3)
  • Fig. 126: Rear Mounting Panel, Partial Replacement (Avant) - Welding In (2 Of 3)
  • Fig. 127: Rear Mounting Panel, Partial Replacement (Avant) - Welding In (3 Of 3)
  • Fig. 128: Rear Lock Carrier, Replacement - Cutting Locations
  • Fig. 129: Rear Lock Carrier, Replacement - Replacement Parts
  • Fig. 130: Rear Lock Carrier, Replacement - Welding In
  • Fig. 131: Side Panel, Replacement - Cutting Locations
  • Fig. 132: Side Panel, Replacement - Replacement Parts
  • Fig. 133: Side Panel, Replacement - Welding In (1 Of 3)
  • Fig. 134: Side Panel, Replacement - Welding In (2 Of 3)
  • Fig. 135: Side Panel, Replacement - Welding In (3 Of 3)
  • Fig. 136: Side Panel, Replacement (Avant) - Cutting Locations
  • Fig. 137: Side Panel, Replacement (Avant) - Replacement Parts
  • Fig. 138: Side Panel, Replacement (Avant) - Welding In (1 Of 2)
  • Fig. 139: Side Panel, Replacement (Avant) - Welding In (2 Of 2)
• TABLES

ACCESSORIES & EQUIPMENT

Body Collision Repair

00 - Technical data

Vehicle identification data

Type plate and vehicle identification number

Fig. 1: Locating Type Plate And Vehicle Identification Number
Courtesy of VOLKSWAGEN UNITED STATES, INC.

The type plate is located on the left suspension turret below the cover support.

Vehicles for certain export countries have no type plate.

The vehicle identification number (VIN) - B - (chassis number) is stamped on the rear bulkhead in the engine compartment.

Vehicle data sticker

Fig. 2: Identifying Vehicle Data Sticker
Courtesy of VOLKSWAGEN UNITED STATES, INC.

The vehicle data sticker is located in the spare wheel well at the rear of the vehicle.

Aluminum panels

Sill reinforcement

Fig. 3: Sill Reinforcement
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Aluminum panels are used on the following parts of the car body: article, General notes; Repair procedures

Foam-filled cavities

A-pillar

Fig. 4: Foam-Filled Cavities - A-Pillar
Courtesy of VOLKSWAGEN UNITED STATES, INC.

a - Foam-filling hole

The following parts of the body are foam-filled for acoustic reasons:

A-pillar

Front longitudinal member

Fig. 5: Identifying Foam Insert & Expanded Foam Insert
Courtesy of VOLKSWAGEN UNITED STATES, INC.

A - Foam insert

Can be re-used. Do not make separating cut in this area. Glue in part with window adhesive.

B - Expanded foam insert

In front longitudinal member

C-pillar

Fig. 6: Identifying Foam-Filling Hole, Expanded Foam Inserts & Dampening Foam
Courtesy of VOLKSWAGEN UNITED STATES, INC.

A - Foam-filling hole

B - Expanded foam insert

Can be re-used; secure with two-part component foam.

C - Expanded foam insert

Can be re-used; secure with two-part component foam.

D - Dampening foam

In rear longitudinal member

Body panel gaps/shut lines

Body, front

Fig. 7: Identifying Body Panel Gaps/Shut Lines (Body, Front)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

N - 0.0 mm

D - 2.0 mm

E - 2.5 mm

F - 3.0 mm

G - 3.5 mm

H - 4.0 mm + 1

K - 5.0 mm

Use special tool 3371 for checking or adjusting.

Body, center

Fig. 8: Identifying Body Panel Gaps/Shut Lines (Body, Center)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

N - 0.0 mm

G - 3.5 mm + 1

H - 4.0 mm + 1

Body, rear

Fig. 9: Identifying Body Panel Gaps/Shut Lines (Body, Rear)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

D - 2.0 mm

E - 2.5 mm

F - 3.0 mm

K - 5.0 mm

Laser welding

Laser welding

Audi has introduced laser welding for the production of the Audi A4.

The laser welding technique employs a high-energy light beam directed onto the weld by means of optical lenses or fiber optics.

During the welding process, the upper panel is welded onto the partially melted lower panel, creating a weld joint with no additional material.

When performing repairs, laser weld seams are replaced by SG welds or pop rivets.

Laser welding (Sedan)

Fig. 10: Identifying C-Pillar Laser-Welded To Inner Side Panel & Roof Laser-Welded To Outer Roof Frame
Courtesy of VOLKSWAGEN UNITED STATES, INC.

A - C-pillar laser-welded to inner side panel

4 x SG continuous seam in place of laser weld

B - Roof laser-welded to outer roof frame

Roof is repaired using SG plug weld seam in place of laser weld.

Fig. 11: Identifying Inner A-Pillar To Inner Side Panel, Inner B-Pillar To Inner Sill & Lock Reinforcement To Inner Side Panel
Courtesy of VOLKSWAGEN UNITED STATES, INC.

C - Inner A-pillar to inner side panel

5 x SG plug weld seam in place of laser weld

D - Inner B-pillar to inner sill

10 x SG plug weld seam in place of laser weld

E - Lock reinforcement to inner side panel

4 x SG plug weld seam in place of laser weld

Bonded joints

Bonded joints

Fig. 12: Bonded Joints
Courtesy of VOLKSWAGEN UNITED STATES, INC.

In the case of the bonded joints, the joint between the sheet metal parts is formed only by the adhesive.

Spot-welded bonded joints

Fig. 13: Spot-Welded Bonded Joints
Courtesy of VOLKSWAGEN UNITED STATES, INC.

In spot welded bonded joints, an electrically conductive adhesive is used between the panels, which allows problem free penetration for spot welding.

The welding current must not be increased during spot-weld bonding. The pre-press time must be extended to about 30 - 50 seconds because of the displacement of the adhesive. The emitted fumes must be extracted.

Spot-weld bonding is not performed in the service department.

Bonded joints, inspecting and repairing

Special attention should be paid to these areas in accident diagnosis and repair work.

Note the following points: Do not test strength using a chisel or relieve tension by hammering, otherwise the bond will be destroyed.

These joints should be inspected particularly closely when diagnosing accident damage and after performing straightening work on the body.

If the joint is not accessible with pop rivets, it must be repaired with an arc-welded seam (SG). In this case the entire area of the joint must be re-welded, as the heat produced by welding destroys the adhesive in the bonded joint. The SG seams should be welded working from the thin to the thick panel. Always extract fumes.

Repair methods for replacing body parts

When making repairs, welded joints can be used in place of all spot-welded bonded joints and certain bonded joints if no suitable body adhesive is available.

Do not make the repair with only the same spot welds or seams as originally used in production. These alone are not adequate for a proper joint.

The repair methods are shown in detail on the following information.

NOTE:

If the instructions call for additional spot welds, these should be applied in a single operation. Do not place new spot welds in-between the original spot welds. SG plug welding should only be performed after spot welding. This avoids any warping when spot welding.

Ensure good root penetration at all joints.

Seal off repaired joint flanges and apply cavity sealing where necessary.

Repair methods for bonded joints

Body, front

Fig. 14: Identifying Repair Methods For Bonded Joints (Body, Front - A, B ,C, D, E, F, X)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

A - Wheel housing to longitudinal member

Make additional 5 x SG plug weld seam in place of bonded joint

B - Longitudinal member reinforcement

With support, make additional 2 x 15 mm SG seams on flange

C - Longitudinal member reinforcement

With support, make additional SG plug weld seams between spot welds

D - Longitudinal member to closure plate and wheel housing (rear section)

Make additional SG plug weld seams between spot welds Longitudinal member to closure plate: make double number of RP spot welds in place of bonded joint.

E - Longitudinal member closure plate to mounting for suspension strut cross member

Make additional 6 x SG plug weld seams in place of bonded joint

F - Inner side panel to outer side panel

Make additional 6 x SG plug weld seams in place of bonded joint

X - Body, center

Fig. 15: Identifying Repair Methods For Bonded Joints (Body, Front - G, H)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

G - Front panel of plenum chamber

To suspension strut mounting: make additional SG plug weld seams between spot welds

H - Cross member to longitudinal member

Make additional SG seam every 15 mm on the 3 flanges

Fig. 16: Identifying Repair Methods For Bonded Joints (Body, Front - J, K, M)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

J - Cross member to plenum chamber

Make additional SG plug weld seams between spot welds

K - Cross member to suspension strut mounting

Make additional 3 x 15 mm SG seams on flange.

M - Reinforcement for suspension strut cross member to connecting panel on longitudinal member (top)

Make additional SG plug weld seams between spot welds

Body, center

Fig. 17: Identifying Repair Methods For Bonded Joints (Body, Center - A, B)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

A - Roof to outer roof frame: as original joint

Apply body adhesive and make spot welds, but leave 15 mm either side of spot welds free of adhesive.

B - Sunroof reinforcing frame to outer roof frame

As original joint. Apply adhesive and insert roof.

Fig. 18: Identifying Repair Methods For Bonded Joints (Body, Center - C)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

C - Front floor panel to sill fillet plate

Make SG plug weld seams every 30 mm in place of bonded joint

Fig. 19: Identifying Repair Methods For Bonded Joints (Body, Center -D)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

D - Rear panel to floor panel

Make additional 8 x 30 mm SG continuous seams

Body, rear

Fig. 20: Identifying Repair Methods For Bonded Joints (Body, Rear - A)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

A - As original joint: apply adhesive and bead over edge of wheel housing. Repair as follows if adhesive joint is damaged.

Brush area, apply paint finish, seal and apply cavity sealing. If adhesive joint is damaged over a length of more than 100 mm, make a 10 mm SG seam every 50 mm. Rework wheel housing liner if necessary.

Straightening jig

Straightening jig

Fig. 21: Straightening Jig (1 Of 10)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

The item numbers in the illustrations are identical with the end numbers on the alignment bracket mountings. The item numbers of the alignment bracket mountings marked with a circle are for checking the body with mechanical units installed. The required basic size is given for the alignment bracket mountings. The following figures show the right side of the vehicle.

Straightening bracket set supplement VAS 6050 (incl. quattro models)

2 - MZ 141 and TV 400

4 - MZ 141, TV 400 and mounting - 2 -

6 - MZ 140

10 - MZ 260

12 - MZ 260 and alignment bracket mounting - 10 -

16 - Mounting for bar

17 - Bar in place of steering gear

18 - Mounting for steering assembly

20 - MZ 140

22 - Bracket without MZ, and front production mounting - 24 -

24 - Mountings identical on left and right sides

26 - MZ 080

28 - MZ 080

30 - MZ 200

32 - MZ 602

33 - Spacer, identical on left and right sides

34 - MZ 260

36 - MZ 260

Fig. 22: Straightening Jig (2 Of 10)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

2 - MZ 200 and TV 400

6 - MZ 140

10 - MZ 260

20 - MZ 140

26 - MZ 080

28 - MZ 080

30 - MZ 200

32 - MZ 602

34 - MZ 260

36 - MZ 260

Overview and locations of MZ elements

Fig. 23: Straightening Jig (3 Of 10)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

8 - MZ 080

20 - MZ 080

22 - Bracket without MZ, and front production mounting - 24 -

26 - MZ 080

28 - MZ 080

30 - MZ 140

34 - MZ 200

36 - MZ 260

Overview of front alignment bracket positions with MZ elements for vehicles with mechanical units installed

Fig. 24: Straightening Jig (4 Of 10)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

2 - Front longitudinal member

When checking body, bolt on this MZ last, as the longitudinal position of the impact absorber mounting can vary by several mm due to production tolerances - if necessary do not bolt down.

4 - Front end of longitudinal member/wheel housing

Overview of front alignment brackets

Fig. 25: Straightening Jig (5 Of 10)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Overview of front alignment brackets

Fig. 26: Straightening Jig (6 Of 10)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

6 - Mounting for subframe

Re-drill master hole when performing partial replacement. Prepare by drilling with 8 mm bit through drill guide and then drill out to 20 mm with a center-bit.

10 - Mounting for alignment brackets - 12 - and - 14 -

Do not insert pin until after fitting body on jig.

13 - Bolts for suspension strut mounting

14 - Bolt for suspension strut mounting

12 - Suspension strut mounting

16 - Mounting for bar

17 - Bar in place of steering gear

Lubricate bar with oil and take care to avoid damage.

18 - Mounting for steering

19 - Mounting for steering

Fig. 27: Straightening Jig (7 Of 10)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Overview of center alignment brackets

Fig. 28: Straightening Jig (8 Of 10)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

20 - Mounting for subframe

22 - Bracket

23 - Front production mounting

May have been forced upwards by handling vehicle in factory: when checking dimensions, pack with spacer up to 4 mm if necessary.

26 - Drilling in longitudinal member

28 - Drilling in sill panel

Fig. 29: Straightening Jig (9 Of 10)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Overview of rear alignment brackets

Fig. 30: Straightening Jig (10 Of 10)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

30 - Mounting in longitudinal member

32 - Suspension strut mounting

Do not insert pin until after fitting body on jig.

36 - Drilling in longitudinal member

The drilling is covered over with fabric-backed tape and sprayed over with underbody sealer. Re-seal drilling after checking body.

Supplement for quattro versions

Fig. 31: Supplement For Quattro Versions (1 Of 3)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

38 - MZ 080

38 - Mounting for driveshaft

Fig. 32: Supplement For Quattro Versions (2 Of 3)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Overview of alignment bracket positions for quattro versions

Fig. 33: Supplement For Quattro Versions (3 Of 3)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

38 - Mounting for driveshaft

Portal gauge

Fig. 34: Portal Gauge (1 Of 4)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

A - Extension

B - Telescopic column

C - Cross bar 1200 mm

40 - Mounting for A-pillar

42 - Mounting for B-pillar

40 - MZ 260

42 - MZ 260

Portal gauge supplement VAS 5007/11

Fig. 35: Portal Gauge (2 Of 4)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

A - Extension

B - Telescopic column

C - Cross bar 1200 mm

42 - Mounting for B-pillar

44 - Mounting for C-pillar

42 - MZ 260

44 - MZ 260

Fig. 36: Portal Gauge (3 Of 4)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

A - Extension

B - Telescopic column

C - Cross bar 1200 mm

40 - Mounting for A-pillar

42 - Mounting for B-pillar

40 - MZ 260

42 - MZ 260

Fig. 37: Portal Gauge (4 Of 4)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

A - Extension

B - Telescopic column

C - Cross bar 1200 mm

42 - Mounting for B-pillar

44 - Mounting for C-pillar

42 - MZ 260

44 - MZ 260

Body dimensions

Floor group, front

Fig. 38: Body dimensions - Floor Group, Front
Courtesy of VOLKSWAGEN UNITED STATES, INC.

a - 840 2mm

Distance between front attachment points of front suspension

b - 620 2mm

Distance between rear attachment points of front suspension

c - 933 2mm

Diagonal distance between attachment points of front suspension

CAUTION:

These dimensions are only used for checking only. Correct dimensions are defined by the alignment bracket set.

Floor group, center

Fig. 39: Body Dimensions - Floor Group, Center
Courtesy of VOLKSWAGEN UNITED STATES, INC.

d - 1993 2mm

Distance between rear attachment points of front suspension and rear axle mounting

e - 2250 2mm

Diagonal distance between rear attachment points of front suspension and rear axle mounting

CAUTION:

These dimensions are only used for checking only. Correct dimensions are defined by the alignment bracket set.

Floor group, rear

Fig. 40: Body Dimensions - Floor Group, Rear
Courtesy of VOLKSWAGEN UNITED STATES, INC.

f - 1090 2mm

Distance between axle mountings

g - 1355 2mm

Diagonal distance between axle mounting and longitudinal member

h - 995 2mm

Distance between rear longitudinal members

CAUTION:

These dimensions are only used for checking only. Correct dimensions are defined by the alignment bracket set.

Body, front

Fig. 41: Body Dimensions - Body, Front (1 Of 2)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

a - 820 2mm

Distance between front longitudinal members

CAUTION:

These dimensions are only used for checking only. Correct dimensions are defined by the alignment bracket set.

Fig. 42: Body Dimensions - Body, Front (2 Of 2)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

b - 1405 2mm

Distance between front hinge mountings

c - 1287 2mm

Distance between wing panel mountings

d - 1560 2mm

Diagonal distance between hinge mountings and wing panel mountings

e - 840 2mm

Distance between outer attachment points of suspension strut mountings

CAUTION:

Distance - e - only serves as a check. Correct dimensions are defined by the alignment bracket set.

Body, center

Front door opening

Fig. 43: Body Dimensions - Body, Center (Front Door Opening)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

a - 1400 2mm

Distance between A-pillars

b - 1443 2mm

Distance between B-pillars

c - 970 2mm

Height of door opening

d - 870 2mm

Distance between A-pillar and B-pillar

CAUTION:

These dimensions are only used for checking only. Correct dimensions are defined by the alignment bracket set.

Body, center (Avant models - interior)

Fig. 44: Body Dimensions - Body, Center (Avant Models - Interior)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

o - 1315 2mm

Distance between mountings for folding backrest

p - 1247 2mm

Distance between seat belt anchorages

Rear door opening

Fig. 45: Body Dimensions - Body, Center (Rear door opening)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

e - 1380 2mm

Distance between C-pillars

f - 1032 2mm

Height of door opening

g - 850 2mm

Distance between B-pillar and C-pillar

CAUTION:

These dimensions are only used for checking only. Correct dimensions are defined by the alignment bracket set.

Rear door opening (Avant)

Fig. 46: Body Dimensions - Body, Center (Rear Door Opening (Avant))
Courtesy of VOLKSWAGEN UNITED STATES, INC.

h - 1382 2mm

Distance between C-pillars

i - 850 2mm

Distance between B-pillar and C-pillar

j - 1447 2mm

Distance between B-pillars

k - 1047 2mm

Height of door opening

CAUTION:

These dimensions are only used for checking only. Correct dimensions are defined by the alignment bracket set.

Body, rear

Fig. 47: Body Dimensions - Body, Rear
Courtesy of VOLKSWAGEN UNITED STATES, INC.

h - 1096 2mm

Distance between side panels (top)

j - 495 2mm

Distance between rear cross panel flange and flange on window cross member

k - 1080 2mm

Distance between rear longitudinal members

Body, rear (Avant)

Fig. 48: Body Dimensions - Body, Rear (Avant)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

l - 1080 2mm

Distance between rear longitudinal members

m - 1205 2mm

Distance between side panels (bottom)

n - 1005 2mm

Distance between side panels (top)

p - 922 2mm

Distance between roof flange and rear cross panel flange

50 - Body, Front

Intermediate piece, partial replacement

Procedure

Cutting locations

Fig. 49: Intermediate Piece, Partial Replacement - Cutting Locations
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Separate original joint.
• Remove remaining material.
• Remove part.

Replacement parts

• Connecting plates

Preparing replacement parts

Fig. 50: Intermediate Piece, Partial Replacement - Replacement Parts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Drill 7 mm holes for SG plug weld seam.

Welding in

Fig. 51: Intermediate Piece, Partial Replacement - Welding In (1 Of 2)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Spot weld intermediate piece: RP spot weld seam.
• Weld in replacement part: SG plug weld seam.

Fig. 52: Intermediate Piece, Partial Replacement - Welding In (2 Of 2)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Install reinforcement and weld in: RP spot weld seam.

Upper wheel housing longitudinal member, replacement

Procedure

Cutting locations

Fig. 53: Upper Wheel Housing Longitudinal Member, Replacement - Cutting Locations
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Intermediate piece already removed

• Cut out as shown.
• Separate original joint.
• Remove remaining material.

Replacement part

• Upper wheel housing longitudinal member

Fig. 54: Upper Wheel Housing Longitudinal Member, Replacement - Replacement Part
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Transfer separating cut to replacement part plus 10 mm for overlap. Cut off shaded area.

Welding in

Fig. 55: Upper Wheel Housing Longitudinal Member, Replacement - Welding In
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Spot weld upper wheel housing longitudinal member: RP spot weld seam.
• Butt weld separating cut: SG continuous seam.

Front longitudinal member, partial replacement

Procedure

Cutting locations

Fig. 56: Front Longitudinal Member, Partial Replacement - Cutting Locations
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Dimension - a - = 95 mm
• Cut out longitudinal member.

NOTE:

Separating cut must be a straight line.

Replacement part

Fig. 57: Front Longitudinal Member, Partial Replacement - Replacement Part
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Sub-part - longitudinal member

Welding in

Fig. 58: Front Longitudinal Member, Partial Replacement - Welding In
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Dimension - b - = 240 mm
• Adapt length on body side of joint if necessary.

NOTE:

Align longitudinal member with lock carrier, cross member and headlight to bumper.

• Weld in front longitudinal member: SG continuous seam 8 x 15 mm.
• Seal weld seam.

Front longitudinal member, replacement

Procedure

Cutting locations

Fig. 59: Front Longitudinal Member, Replacement - Cutting Locations (1 Of 2)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Separate original joint between inner longitudinal member and reinforcement plates.
• Separate original joint between upper longitudinal member and support.
• Grind off weld seams on longitudinal member.
• Take out inner longitudinal member.

• Remove remaining material.

Fig. 60: Front Longitudinal Member, Replacement - Cutting Locations (2 Of 2)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Drill off reinforcing plate - a - so that it can be re-used.
• Make separating cut - b - at bottom as shown and bend panel out (see inset).
• Make separating cut in longitudinal member as shown. Take care not to damage internal reinforcement.
• Use grinder to make separating cut.

CAUTION:

If the inner longitudinal member is damaged it must also be replaced.

• Separate original joint.

Replacement parts

• Inner longitudinal member
• Longitudinal member

Preparing replacement parts

Fig. 61: Front Longitudinal Member, Replacement - Replacement Parts (1 Of 2)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Drill 7 mm holes for SG plug weld seam.

Fig. 62: Front Longitudinal Member, Replacement - Replacement Parts (2 Of 2)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Transfer separating cut to replacement part and cut off shaded area.
• Drill off reinforcements

Welding in

Fig. 63: Front Longitudinal Member, Replacement - Welding In (1 Of 4)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Install replacement parts and secure on alignment bracket.
• Butt weld separating cut: SG continuous seam.

Fig. 64: Front Longitudinal Member, Replacement - Welding In (2 Of 4)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Bend back wheel housing reinforcing plate and weld in: SG continuous seam.
• Weld in support plate: SG plug weld seam
• Weld in remaining joint: SG plug weld seam.

Fig. 65: Front Longitudinal Member, Replacement - Welding In (3 Of 4)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Weld in replacement part: SG continuous seam.
• Weld in reinforcing plate: SG plug weld seam.

Fig. 66: Front Longitudinal Member, Replacement - Welding In (4 Of 4)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Weld in longitudinal member: SG plug weld seam.
• Spot weld longitudinal member: RP spot weld seam.

51 - Body, center

Roof, replacing

Procedure

Cutting locations

Fig. 67: Roof, Replacing - Cutting Locations (1 Of 3)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Separate original joint.

NOTE:

This description covers the repair method with riveting and bonding as well as shielded arc welding (SG). A special hose set with reduced nozzle diameter is required for the shielding gas welding unit when performing repairs on the roof. Hose set for shielding gas welding unit VAS 5023

Fig. 68: Roof, Replacing - Cutting Locations (2 Of 3)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• On vehicles with sun roof, cut through bond points with a knife.

Fig. 69: Roof, Replacing - Cutting Locations (3 Of 3)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Grind surface of laser weld seam and use chisel to bend up remaining pieces and pry off.
• Remove sealing compound from sealing channel.

NOTE:

Only grind surface of laser weld seam. Do not grind through roof. If the roof frame is damaged, this must also be replaced.

• Remove remaining material.

Replacement parts

• Roof
• Body adhesive DA 001 730 A1
• Assembly adhesive D 190 MKD A3
• Pop rivet 3.2 x 6.6 N 907 979 01

Preparing replacement part

Fig. 70: Roof, Replacing - Replacement Parts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Mark positions of spot welds - a - , - b - , - c - and rivet holes with soft pencil.

NOTE:

If the replacement roof panel is not going to be riveted and bonded, make holes in replacement part for SG plug weld seam in the area of the rivet holes.

• Mount on roof and install in position.

CAUTION:

Check fit with windshield and rear window. It is important to maintain dimension - a - of 12 + 1 mm for roof joint strip.

• Drill 3.2 mm rivet holes at the points illustrated. Remove roof and de-burr holes.
• Grind down bonding surface on body to bare metal.
• Grind off primer only in vicinity of spot welds.
• Clean bonding area (it must be free of dust and grease).

Welding in

Fig. 71: Roof, Replacing - Welding In (1 Of 3)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• On vehicles with sunroof, apply assembly adhesive in the area of the roof reinforcement.
• Apply adhesive. Diameter of adhesive bead approx. 3.5 mm. Leave 15 mm either side of spot welds free of adhesive.

CAUTION:

The replacement part must be welded in within 30 minutes, otherwise the strength of the adhesive joint will be impaired.

• Mount on roof and install in place. Press in roof at sealing channel in order to force out adhesive.

NOTE:

If adhesive comes out on both sides over the full length of the joint, this indicates that sufficient adhesive has been applied.

Fig. 72: Roof, Replacing - Welding In (2 Of 3)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Install pop rivets.
• Wipe off adhesive emerging from joint.
• Apply sealant (2 mm thick) in sealing channel.
• Weld in roof: RP spot weld seam.

NOTE:

The seal must be even and thin. Unevenness will be visible on the roof trim strip (wavy).

Fig. 73: Roof, Replacing - Welding In (3 Of 3)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Weld in roof: RP spot weld seam.
• Weld in replacement part: SG plug weld seam.

Roof, replacement (Avant)

Procedure

Cutting locations

Fig. 74: Roof, Replacement (Avant) - Cutting Locations (1 Of 3)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Roughly cut out roof.

NOTE:

Cut out roof reinforcement as well.

Fig. 75: Roof, Replacement (Avant) - Cutting Locations (2 Of 3)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• On vehicles with sunroof, cut through bond points with a knife.
• Remove sealing compound from sealing channel.

Fig. 76: Roof, Replacement (Avant) - Cutting Locations (3 Of 3)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Grind surface of laser weld seam and use chisel to bend up remaining pieces and pry off.

NOTE:

Only grind surface of laser weld seam. Do not grind through roof. If the roof frame is damaged, this must also be replaced.

• Remove remaining material.

Replacement parts

• Roof
• Butyl adhesive sealing cord AKL 450 005 05
• Body adhesive DA 001 730 A1
• Assembly adhesive D 190 MKD A3

• Pop rivet 3.2 x 6.6 N 907 979 01

Preparing replacement part

Fig. 77: Roof, Replacement (Avant) - Replacement Parts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Mark positions of spot welds - a - , - b - , - c - , - d - and rivet holes with soft pencil.

NOTE:

If the replacement roof panel is not going to be riveted and bonded, make holes in replacement part for SG plug weld seam in the area of the rivet holes. On vehicles with foam-filled B-pillar, make holes for SG plug weld seam in vicinity of spot welds - A - and - B - instead of drilling rivet holes.

• Mount on roof and install in position.

CAUTION:

Check fit with windshield and rear window. It is important to maintain dimension of 12 + 1 mm for roof joint strip.

• Drill 3.2 mm rivet holes at the points illustrated. Remove roof and de-burr holes.
• Grind down bonding surface on body to bare metal.
• Grind off primer only in vicinity of spot welds.
• Clean bonding area (it must be free of dust and grease).

Welding in

Fig. 78: Roof, Replacement (Avant) - Welding In (1 Of 4)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Place a 150 mm length of butyl cord centrally over tailgate hinge cut-out on roof cross member.
• On vehicles with sunroof, apply assembly adhesive in the area of the roof reinforcement.
• Apply adhesive. Diameter of adhesive bead approx. 3.5 mm. Leave 15 mm either side of spot welds free of adhesive.

CAUTION:

The replacement part must be welded in within 30 minutes, otherwise the strength of the adhesive joint will be impaired.

• Mount on roof and install in position. Press in roof at sealing channel in order to force out adhesive.

NOTE:

If adhesive comes out on both sides over the full length of the joint, this indicates that sufficient adhesive has been applied.

Fig. 79: Roof, Replacement (Avant) - Welding In (2 Of 4)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Install pop rivets.
• Wipe off adhesive emerging from joint.
• Apply sealant (2 mm thick) in sealing channel.

NOTE:

The seal must be even and thin. Unevenness will be visible on the roof trim strip (wavy).

Fig. 80: Roof, Replacement (Avant) - Welding In (3 Of 4)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Weld in roof: RP spot weld seam.
• Weld in replacement part: SG plug weld seam.

Fig. 81: Roof, Replacement (Avant) - Welding In (4 Of 4)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Weld in roof: RP spot weld seam.
• Braze in roof.
• Working from interior, fill gap between roof and roof frame (front and rear) with sealant.

Front roof cross member, replacement

Procedure

Cutting locations

Fig. 82: Front Roof Cross Member, Replacement - Cutting Locations
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Roof already removed

• Roughly cut out roof frame.
• Separate original joint.
• Remove remaining material.

NOTE:

This joint is additionally bonded. Make additional 2 x 10 mm SG continuous seams in place of bonded joints.

Replacement part

• Roof cross member

Welding in

• Install replacement part in position.

Fig. 83: Front Roof Cross Member, Replacement - Welding In
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Weld in replacement part: RP spot weld seam.
• Weld remaining joint: staggered SG continuous seam.
• Place butyl cord over roof cut-out (2 x 200 mm on the outside and 1 x 200 mm in the center).

Rear roof frame, replacement

Procedure

Cutting locations

Fig. 84: Rear Roof Frame, Replacement - Cutting Locations
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Roof already removed

• Roughly cut out roof frame.
• Separate original joint.
• Remove remaining material.

NOTE:

This joint is additionally bonded. Make additional 2 x 10 mm SG continuous seams in place of bonded joints.

Replacement part

• Roof frame
• Butyl adhesive sealing cord AKL 450 005 05

Welding in

• Mount and install replacement part in position.

Fig. 85: Rear Roof Frame, Replacement - Welding In
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Weld in replacement part: RP spot weld seam.
• Weld remaining joint: staggered SG continuous seam.
• Place 2 x 200 mm lengths of butyl cord centrally over tailgate hinge cut-out and 2 x 260 mm on roof cross member.

Rear roof frame, replacement (Avant)

Procedure

Cutting locations

Fig. 86: Rear Roof Frame, Replacement (Avant) - Cutting Locations
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Roof already removed

• Separate original joint.
• Drill out spot welds - a - from inside.

Replacement parts

• Rear roof frame
• Rear roof frame (inner)

Welding in

• Mount and install replacement part in position.
• Weld in replacement part: SG plug weld seam.

Fig. 87: Rear Roof Frame, Replacement (Avant) - Welding In (1 Of 2)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Align replacement part over hole - arrow - in rear roof frame (inner).

Fig. 88: Rear Roof Frame, Replacement (Avant) - Welding In (2 Of 2)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Weld in replacement part: RP spot weld seam.

A-pillar, replacement

Procedure

Cutting locations

Fig. 89: A-Pillar, Replacement - Cutting Locations
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Make separating cut at top according to extent of damage. Do not cut in vicinity of inner reinforcement.
• Do not damage inner reinforcement when making separating cut in sill.
• Separate original joint.

NOTE:

Partial replacement is possible using separating cuts as listed. Offset in area of separation and apply SG plug weld seam.

Replacement parts

• A-pillar (sub-part)

Preparing replacement part

Fig. 90: A-Pillar, Replacement - Cutting Locations
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Transfer separating cut to replacement part and cut to fit.
• Drill 7 mm holes for SG plug weld seam.

Welding in

Fig. 91: A-Pillar, Replacement - Welding In
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Place backing plate of same material behind separating cuts.
• Weld in A-pillar: RP spot weld seam.
• Butt weld separating cuts: SG continuous seam.
• Make additional weld at A-pillar: SG plug weld seam.

Inner A-pillar, replacement

Procedure

Cutting locations

Fig. 92: Inner A-Pillar, Replacement - Cutting Locations
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• A-pillar already cut out

• Separate original joint.
• Remove remaining material.
• Remove inner A-pillar from below.

Replacement part

• Inner A-pillar

Preparing replacement part

Fig. 93: Inner A-Pillar, Replacement - Replacement Part
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Drill 7 mm holes for SG plug weld seam.

Welding in

Fig. 94: Inner A-Pillar, Replacement - Welding In
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Weld in inner A-pillar: RP spot weld seam.
• Weld in A-pillar: SG plug weld seam.

B-pillar, replacement

Procedure

Cutting locations

Fig. 95: B-Pillar, Replacement - Cutting Locations
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Cut inner B-pillar below welded nut for seat belt anchorage.
• Separate original joint.

Replacement part

• B-pillar (sub-part)

Preparing replacement parts

Fig. 96: B-Pillar, Replacement - Replacement Part
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Transfer separating cut to replacement part and cut off shaded area.
• Drill 7 mm holes for SG plug weld seam.

Welding in

• Place backing plate of same material behind separating cuts.

Fig. 97: B-Pillar, Replacement - Welding In
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Mount inner B-pillar with vehicle free of stress and install in position.
• Weld in B-pillar: RP spot weld seam.
• Weld in B-pillar: SG plug weld seam.
• Butt weld separating cuts: SG continuous seam.

Inner B-pillar, replacement

Procedure

Cutting locations

Fig. 98: Inner B-Pillar, Replacement - Cutting Locations
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Cut out as shown.
• Separate original joint.

Replacement parts

• Inner B-pillar

Preparing replacement part

Fig. 99: Inner B-Pillar, Replacement - Replacement Parts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Transfer separating cut to replacement part and cut out.

Welding in

Fig. 100: Inner B-Pillar, Replacement - Welding In
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Mount inner B-pillar with vehicle free of stress and install in position.
• Weld in inner B-pillar: SG continuous seam.
• Butt weld separating cut: SG continuous seam.
• Spot weld B-pillar - RP spot weld seam.

Inner side member, replacement

Procedure

Cutting locations

Fig. 101: Inner Side Member, Replacement - Cutting Locations
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Outer side member, B-pillar (part section), outer A-pillar and inner A-pillar already cut out

• Separate original joint.
• Open laser weld at inner B-pillar
• Side member does not have to be renewed if deformation is no greater than 5 mm.

Replacement part

• Inner side member

Fig. 102: Inner Side Member, Replacement - Replacement Part
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Drill 7 mm holes for SG plug weld seam.

Welding in

Fig. 103: Inner Side Member, Replacement - Welding In
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Weld in side member: RP spot weld seam.
• Weld in side member: SG plug weld seam.
• Weld laser seam: SG continuous seam.

Floor panel, partial replacement

Procedure

Cutting locations

Fig. 104: Floor Panel, Partial Replacement - Cutting Locations
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Separate original joint.
• Grind off MIG brazed seam and make SG continuous seam in its place.
• Cut out as shown. Take care not to damage internal reinforcement or longitudinal member.

Replacement part

• Floor panel

Preparing replacement part

Fig. 105: Floor Panel, Partial Replacement - Replacement Part
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Transfer separating cut to replacement part plus 15 mm for overlap. Cut off shaded area.
• Drill 7 mm holes for SG plug weld seam.

Welding in

• Offset separating cut (on body side of joint).

Fig. 106: Floor Panel, Partial Replacement - Welding In
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Weld in replacement part: SG plug weld seam.
• Weld in floor panel: 25 mm SG continuous seam with 20 mm spacing.

53 - Body, rear

Rear cross panel (upper section), replacement

Procedure

Cutting locations

Fig. 107: Rear Cross Panel (Upper Section), Replacement - Cutting Locations
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Separate original joint.
• Remove part.

Replacement part

Fig. 108: Rear Cross Panel (Upper Section), Replacement - Replacement Part
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Rear cross panel

Welding in

Fig. 109: Rear Cross Panel (Upper Section), Replacement - Welding In
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Spot weld rear cross panel: RP spot weld seam.

Rear cross panel (upper section), replacement (Avant)

Procedure

Cutting locations

Fig. 110: Rear Cross Panel (Upper Section), Replacement (Avant) - Cutting Locations
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Separate original joint.

Replacement part

• Rear cross panel

Preparing replacement part

Fig. 111: Rear Cross Panel (Upper Section), Replacement (Avant) - Replacement Part
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Make holes in outer joint surface of replacement part.

Welding in

Fig. 112: Rear Cross Panel (Upper Section), Replacement (Avant) - Welding In
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Spot weld rear cross panel: RP spot weld seam.
• Weld in rear cross panel: SG plug weld seam.
• Make 3 x SG plug weld seam in place of bonded joint

Rear cross panel (upper section), replacement

Procedure

Cutting locations

Fig. 113: Rear Cross Panel (Upper Section), Replacement - Cutting Locations
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Upper section of rear cross panel already removed

• Separate original joint.
• Remove part.

Replacement part

• Rear cross panel

Welding in

Fig. 114: Rear Cross Panel (Upper Section), Replacement - Welding In
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Spot weld rear cross panel: RP spot weld seam.

Rear cross panel (inner section), replacement

Procedure

Cutting locations

Fig. 115: Rear Cross Panel (Inner Section), Replacement - Cutting Locations
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Upper section of rear cross panel already removed

• Separate original joint.
• - a - = Drill through tail light mounting (two metal thicknesses).
• Remove part.

Replacement part

• Reinforcement for rear cross panel

Preparing replacement part

Fig. 116: Rear Cross Panel (Inner Section), Replacement - Replacement part
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Drill 7 mm holes for SG plug weld seam.

Welding in

Fig. 117: Rear Cross Panel (Inner Section), Replacement - Welding In
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Guide in part from above between tail light mounting and bottom reinforcement.
• Weld in replacement part: RP spot weld seam.
• Weld in remaining joint: SG plug weld seam.

Rear cross panel (inner section), replacement (Avant)

Procedure

Cutting locations

Fig. 118: Rear Cross Panel (Inner Section), Replacement (Avant) - Cutting Locations
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Upper section of rear cross panel already removed

• Separate original joint.
• Rotate part towards the inside and remove - arrow -.

Replacement part

• Reinforcement for rear cross panel

Welding in

Fig. 119: Rear Cross Panel (Inner Section), Replacement (Avant) - Welding In
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Guide in part from above between tail light mounting and bottom reinforcement.
• Spot weld rear cross panel: RP spot weld seam.

Tail light mounting, replacement

Procedure

Cutting locations

Fig. 120: Tail Light Mounting, Replacement - Cutting Locations
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Upper section of rear cross panel already cut out (part section)

• Separate original joint.
• Remove part.

Replacement part

• Tail light mounting

Preparing replacement part

Fig. 121: Tail Light Mounting, Replacement - Replacement Part
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Drill 7 mm holes for SG plug weld seam.

Welding in

Fig. 122: Tail Light Mounting, Replacement - Welding In
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• The cross panel is now tilted into the installation position, pulled up and fitted into place.
• Check gap between new panel and tail light/rear lid.
• Spot weld rear cross panel: RP spot weld seam.
• Weld in replacement part: SG plug weld seam.

Rear mounting panel, partial replacement (Avant)

Procedure

Cutting locations

Fig. 123: Rear Mounting Panel, Partial Replacement (Avant) - Cutting Locations
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Rear cross panel already cut out
• Includes: inner reinforcement

• Separate original joint at cross panel and detach part.
• Separate original joint at inner reinforcement and detach part.

Replacement parts

• Metal insert
• Reinforcement

Preparing replacement part

Fig. 124: Rear Mounting Panel, Partial Replacement (Avant) - Replacement Parts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Drill 7 mm holes for SG plug weld seam.

Welding in

Fig. 125: Rear Mounting Panel, Partial Replacement (Avant) - Welding In (1 Of 3)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Align contour of inner reinforcement and metal insert. Weld in place: RP spot weld seam.

Fig. 126: Rear Mounting Panel, Partial Replacement (Avant) - Welding In (2 Of 3)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Slide tail light mounting with reinforcement under side panel.

Fig. 127: Rear Mounting Panel, Partial Replacement (Avant) - Welding In (3 Of 3)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Weld metal insert to side panel: SG plug weld seam.
• Weld metal insert to longitudinal member: SG plug weld seam.

Rear lock carrier, replacement

Procedure

Cutting locations

Fig. 128: Rear Lock Carrier, Replacement - Cutting Locations
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Side panel already cut out
• Outer side member (part section) already removed

• Separate original joint.
• Separating cut in lock reinforcement is intended for replacement of sill. Remove part in such a way that it can be re-used. If renewing, place backing plate of same material behind joint.

Replacement parts

• Lock carrier plate

Preparing replacement part

Fig. 129: Rear Lock Carrier, Replacement - Replacement Parts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Drill 7 mm holes for SG plug weld seam.
• Make 5 x SG plug weld seam in place of laser weld.

Welding in

Fig. 130: Rear Lock Carrier, Replacement - Welding In
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Weld in lock carrier: RP spot weld seam.
• Weld in replacement part: SG plug weld seam.

Side panel, replacement

Procedure

Cutting locations

Fig. 131: Side Panel, Replacement - Cutting Locations
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Grind through outer edge of wheel housing.
• Make separating cuts as shown. Do not damage internal reinforcement.
• Separate original joint.
• Grind down laser weld seam in C-pillar.

NOTE:

A partial replacement is possible with the separating cuts illustrated. Place an additional thickness of the same material behind the joint and make SG stepped weld seam.

Replacement parts

• Side panel
• Metal insert
• Body adhesive DA 001 730 A1

Preparing replacement part

Fig. 132: Side Panel, Replacement - Replacement Parts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Transfer separating cut to replacement part and cut off shaded area.
• Grind back C-pillar for SG continuous seam in place of laser weld.
• Drill holes for SG plug weld seam in area of roof and tail light.
• Clean bonding area (it must be free of dust and grease).

• Grind down bonding surface on body to bare metal.
• Clean beaded area (it must be free of dust and grease).

Welding in

• Align flanges on roof and window cross member.

Fig. 133: Side Panel, Replacement - Welding In (1 Of 3)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Weld in side panel: RP spot weld seam.
• Butt weld separating cut: SG continuous seam.
• Apply adhesive to beaded flange. Two beads of adhesive: 3.5 mm diameter.
• Bead over wheel housing flange. Wipe off emerging adhesive and seal joint.

Fig. 134: Side Panel, Replacement - Welding In (2 Of 3)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Weld in side panel: RP spot weld seam.
• Weld in replacement part: SG plug weld seam.

Fig. 135: Side Panel, Replacement - Welding In (3 Of 3)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Weld in side panel: SG plug weld seam.

Side panel, replacement (Avant)

Procedure

Cutting locations

Fig. 136: Side Panel, Replacement (Avant) - Cutting Locations
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Locate C-pillar on portal gauge supplement VAS 5007/11.
• Make separating cut on D-pillar according to extent of damage.
• Roughly cut out D-pillar.
• Make separating cuts in side member according to extent of damage.

• Do not damage inner reinforcement when making separating cut in sill.
• Grind through outer edge of wheel housing.
• Separate original joint.

Replacement parts

• Side panel (sub-part)
• Body adhesive DA 001 730 A1

Preparing replacement part

Fig. 137: Side Panel, Replacement (Avant) - Replacement Parts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Make holes in outer joint surface of replacement part.
• Grind down bonding surface (on body side of joint) to bare metal.
• Clean beaded area (it must be free of dust and grease).
• Apply adhesive to beaded flange. Two beads of adhesive: 3.5 mm diameter.

Welding in

• Align flanges on roof and window cross member.

Fig. 138: Side Panel, Replacement (Avant) - Welding In (1 Of 2)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Weld in side panel: RP spot weld seam.
• Bead over wheel housing flange. Wipe off emerging adhesive and seal joint.

Fig. 139: Side Panel, Replacement (Avant) - Welding In (2 Of 2)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Weld in side panel: SG plug weld seam.
• Butt weld separating cuts: SG stepped seam.

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